End member, gas spring assembly and method

ABSTRACT

An end member for a gas spring assembly includes an end member wall with a first wall portion at least partially defining a substantially-flat surface area in a first plane, a second wall portion at least partially defining an outer peripheral extent of the end member wall and a third wall portion at least partially defining a substantially-flat surface area in a second plane. A valley can extend lengthwise along the third wall portion. A gas spring assembly and method of assembly are also included.

BACKGROUND

The subject matter of the present disclosure broadly relates to the artof gas spring devices and, more particularly, to an end member for a gasspring assembly, as well as a gas spring assembly and method of assemblythat include the same. In particular, an end member in accordance withthe subject matter of the present disclosure is formed from thin-walledmetal material and includes a plurality of substantially-flat wallsections disposed in one of two or more different planes such thatimproved performance in offset mounting arrangements may be achieved.

The subject matter of the present disclosure may find particularapplication and use in conjunction with suspension systems of wheeledvehicles, and may be described herein with reference thereto. However,it is to be appreciated that the subject matter of the presentdisclosure is also amenable to other applications and environments, andthat the specific uses shown and described herein are merely exemplary.For example, the subject matter of the present disclosure could be usedin support structures, height adjusting systems and actuators associatedwith industrial machinery, components thereof and/or other suchequipment.

Certain types of gas spring constructions commonly include a flexiblewall that is secured between opposing end members. Depending upon theoverall type and design of the gas spring, an end member may take theform of a generally flat plate that is secured to an open end of theflexible wall. In some cases, such end members may be referred to in theart as bead plates. Another type or style of end member that is commonlyused is often referred to as a roll-off piston. Such end members have aconsiderably greater height dimension than a bead plate, which permitsthe flexible wall to roll along a side wall of the piston during use, asis well known in the art.

Much attention has been directed to the design and manufacture ofroll-off piston designs in an effort to provide improved performanceduring use in offset mounting arrangements and conditions. Examples ofsuch designs are embodied in U.S. Pat. No. 4,506,910 to Bierens; U.S.Pat. No. 6,024,343 to Ebert; U.S. Pat. No. 6,527,259 to Nemeth, et al.and U.S. Patent Application Publication No. 2008/211150 to Levy, et al.

To enable existing bead plate designs to withstand the forces and loadsthat are commonly associated with offset mounting arrangements, areinforcing plate is sometimes assembled between the bead plate and anoffset structural component (e.g., a main beam of a vehicle chassis) towhich the gas spring is secured. The reinforcing plate is generally ofslightly smaller diameter than the bead plate but is often ofconsiderably greater thickness than the material from which the beadplate is formed. The use of the reinforcing plate can substantiallyincrease the stiffness of the end member and can result in acorresponding reduction in deflection of the bead plate during dynamicuse in operation.

Additionally, or in the alternative, a reinforcing bracket and/or platecan be secured on or along the offset structural component, such as byusing a welded joint or connection, for example. Such a reinforcingbracket and/or plate will typically project outwardly beyond the offsetstructural component (e.g., a main beam of a vehicle chassis) andabuttingly engage the portion of the bead plate that would be otherwiseunsupported by the offset structural component. As such, as mentionedabove, the use of such reinforcing bracket and/or plate cansubstantially increase the stiffness of the end member and can result incorresponding a reduction in deflection of the bead plate during dynamicuse in operation

However, certain disadvantages are also commonly identified as beingassociated with the use of such reinforcing brackets and/or plates.Naturally, it may be desirable to avoid or minimize these and/or otherdisadvantages. For example, the addition and use of such a reinforcingbracket and/or plate increases the material and, thus, the weightassociated with the use of the gas spring assembly. Currently,significant efforts are being made, particularly in vehicle-relatedapplications, to reduce the material usage and thereby reduce the weightof vehicle components. Additionally, the use of additional componentsalso undesirably increases manufacturing and assembly costs associatedwith the same.

In view of the foregoing, it is believed desirable to develop an endmember for a gas spring assembly, as well as a gas spring assembly andmethod of assembling the same, capable of providing improved performancein offset mounting arrangements and/or overcoming other disadvantages ofknown constructions while providing and/or maintaining certain desirablequalities and benefits, such as, for example, a relatively low cost ofmanufacture and ease of assembly.

BRIEF DESCRIPTION

One example of an end member in accordance with the subject matter ofthe present disclosure that is dimensioned for securement to an open endof an associated gas spring flexible wall can include an end member wallhaving an outer peripheral extent and that is formed from thin-walledmetal material. The end member wall can include a first wall portionthat is disposed along the outer peripheral extent and that can includea substantially-flat surface area at least partially defining a firstplane of the end member. A second wall portion can be disposed radiallyoutwardly of the first wall portion and can at least partially definethe outer peripheral extent of the end member wall. The second wallportion can extend from the first wall portion out of the first plane ina first direction. A third wall portion can be disposed radiallyinwardly of at least part of the first wall portion and can include asubstantially-flat surface area and at least one valley extendingdepthwise into the end member wall in the first direction and lengthwiseacross the third wall portion, the substantially-flat surface area atleast partially defines a second plane of the end member. The secondplane can be disposed in approximate alignment with the first plane andin spaced relation to the first plane in a second direction that isgenerally opposite the first direction. A first securement feature canbe disposed along the substantially-flat surface area of the third wallportion and can be adapted to engage an associated external component.

One example of a gas spring assembly in accordance with the subjectmatter of the present disclosure can include a flexible wall thatextends circumferentially around a longitudinal axis and that includes afirst open end and an opposing second open end that is spacedlongitudinally from the first open end. A first end member can besecured across the first open end such that a substantially fluid-tightseal is formed therewith. A second end member can be secured across thesecond open end of the flexible wall in a substantially fluid-tightmanner such that a spring chamber is at least partially defined by theflexible wall between the first and second end members. The second endmember can include an end member wall that has an outer peripheralextent and that is formed from thin-walled metal material. The endmember wall can include a first wall portion that is disposed along theouter peripheral extent and that includes a substantially-flat surfacearea that at least partially defines a first plane of the second endmember. A second wall portion can be disposed radially outwardly of thefirst wall portion and can at least partially define the outerperipheral extent of the end member wall. The second wall portion canextend from the first wall portion out of the first plane in a firstlongitudinal direction. A third wall portion can be disposed radiallyinwardly of at least part of the first wall portion and can include asubstantially-flat surface area and at least one valley extending intothe end member wall. The substantially-flat surface area at leastpartially defines a second plane of the second end member. The secondplane can be disposed in approximate alignment with the first plane andcan be in spaced relation to the first plane in a second longitudinaldirection that is generally opposite the first direction. The at leastone valley can extend depthwise into the end member wall and can extendlengthwise along at least part of the third wall portion.

One example of a method of assembling a gas spring assembly inaccordance with the subject matter of the present disclosure can includean action of providing a flexible wall that extends circumferentiallyabout a longitudinally-extending axis and that extending longitudinallybetween opposing first and second open ends. The method can also includean action of providing a first end member and securing the first endmember across the first open end such that a substantially fluid-tightseal is formed between the first end member and the flexible wall. Themethod can further include an action of providing a second end memberthat includes an end member wall having an outer peripheral extent andthat is formed from thin-walled metal material. The end member wall caninclude a first wall portion disposed along the outer peripheral extentand can include a substantially-flat surface area that at leastpartially defines a first plane of the second end member. A second wallportion can be disposed radially outwardly of the first wall portion andcan at least partially define the outer peripheral extent of the endmember wall. The second wall portion can extend from the first wallportion out of the first plane in a first longitudinal direction. Athird wall portion can be disposed radially inwardly of at least part ofthe first wall portion and can include a substantially-flat surface areaand at least one valley extending into the end member wall. Thesubstantially-flat surface area at least partially defines a secondplane of the second end member. The second plane can be disposed inapproximate alignment with the first plane and can be disposed in spacedrelation to the first plane in a second longitudinal direction generallyopposite the first direction. The at least one valley can extenddepthwise into the end member wall and lengthwise across the third wallportion. The method can also include an action of securing the secondend member across the second open end of the flexible wall such that asubstantially fluid-tight seal is formed between the second end memberand the flexible wall.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a gas spring assembly that includes oneexample of an end member in accordance with the subject matter of thepresent disclosure.

FIG. 2 is a top plan view of the gas spring assembly in FIG. 1.

FIG. 3 is a cross-sectional side view of the gas spring assembly inFIGS. 1 and 2 taken along line 3-3 in FIG. 2.

FIG. 4 is a cross-sectional side view of the gas spring assembly inFIGS. 1-3 taken along line 4-4 in FIG. 2.

FIG. 5 is an enlarged cross-sectional side view of the portion of theend member in FIGS. 1-4 identified in Detail 5 of FIG. 4.

FIG. 6 is an exploded cross-sectional side view of a portion of the endmember and flexible wall in FIGS. 1-4 prior to assembly.

FIG. 7 is a top plan view of another example of an end member inaccordance with the subject matter of the present disclosure shown priorto assembly on a flexible wall.

FIG. 8 is a perspective view of a further example of an end member inaccordance with the subject matter of the present disclosure shown priorto assembly on a flexible wall.

FIG. 9 is a top plan view of the end member in FIG. 8.

FIG. 10 is a cross-sectional side view of a portion of the end member inFIGS. 8 and 9 taken along line 10-10 in FIG. 9.

DETAILED DESCRIPTION

It will be appreciated that a gas spring assembly in accordance with thesubject matter of the present disclosure can be of any suitable type,kind, configuration and/or arrangement having a flexible wall, such asconvoluted bellows-type construction or a rolling lobe-typeconstruction, for example. Generally, such a gas spring assembly caninclude a flexible wall and opposing first and second end members. Inthe case of a convoluted bellows-type construction, the flexible wallcan have one or more convolutions and can include end members that takethe form of low-profile plates that are secured to the ends of theflexible wall. Alternately, a rolling lobe-type construction can includean elongated sleeve-type flexible wall with one end member that takesthe form of a roll-off piston, such as is shown and described herein,for example. It is to be distinctly understood, however, that theembodiments shown and described herein are merely exemplary and that anyother suitable arrangement and/or configuration of gas spring assemblycould alternately be used.

Additionally, it will be appreciated that a gas spring assembly inaccordance with the subject matter of the present disclosure can beinstalled or otherwise secured between spaced-apart structuralcomponents in any suitable manner and/or arrangement. As describedhereinafter, an end member and gas spring assembly in accordance withthe subject matter of the present disclosure may find particularapplication and use in connection with arrangements in which one or bothof the end members of the gas spring assembly are offset or otherwisepartially unsupported by the associated structural components to whichthe end member or end members are secured. However, it is to berecognized that such an end member and/or gas spring assembly areexpected to be capable of broad use and that the specific mountingarrangements shown and described herein are merely exemplary and notintended to be limiting.

Turning, now, to the drawings, which are intended to illustrate examplesof the subject matter of the present disclosure and which are notintended to be in anyway limiting, FIGS. 1-4 illustrate a gas springassembly 100 in accordance with the subject matter of the presentdisclosure that includes a gas spring sleeve or bellows, such as aflexible sleeve 102, for example, a first end member, such as a roll-offpiston 104, for example, and a second end member, such as a bead plate106, for example. Gas spring assembly is disposed between a first orupper structural component USC and a second or lower structuralcomponent LSC that is spaced from the upper structural component.

Flexible sleeve 102 includes a flexible wall 108 that extendscircumferentially around a longitudinal axis AX and longitudinallybetween opposing first and second open ends 110 and 112. Flexible wall108 can be of any suitable type and/or kind and can be constructed fromany suitable material or combination of materials, such as may be knownin the art. As one example, flexible wall 108 can include one or morelayers or plies of elastomeric material (e.g., rubber and/orthermoplastic elastomer) and one or more layers or plies ofreinforcement filaments (e.g., polyamide and/or polyimide fibers). Itwill be appreciated, however, that any other suitable material orcombination of materials could alternately be used.

Flexible sleeve 102 can optionally include a mounting bead disposedalong an end of the flexible wall. In the exemplary embodiment shown,flexible sleeve 102 includes a first mounting bead 114 disposed alongfirst open end 110 and a second mounting bead 116 disposed along secondopen end 112. The first and second mounting beads are shown as includingan optional reinforcement element 118, which is sometimes referred to inthe art as a bead wire, that is at least partially embedded within theflexible wall.

Piston 104 is shown as extending between a first or lower end 120 and asecond or upper end 122 with an outer side wall 124 extending in agenerally longitudinal manner therebetween. In use, flexible wall 108 offlexible sleeve 102 forms a rolling-lobe 126 that is displaced alongside wall 124 as the gas spring undergoes changes in overall height,such as, for example, may be due to variations in load conditionsapplied thereto, as is well understood by those of skill in the art. Itwill be recognized that a wide variety of shapes, profiles and/orconfigurations can and have been used in forming the first or outer sidewall of the piston assembly. As such, it will be appreciated that theprofile or shape of side wall 124 is merely exemplary and that any oneor more portions can be included, such as, for example, may have anapproximately frustoconical or tapered shape, a curvilinear shape and/oran approximately cylindrical shape.

Piston 104 includes a first or lower end wall 128 that extends generallytransverse (e.g., perpendicular) to side wall 124. Lower end wall 128 isshown as abuttingly engaging lower structural component LSC and can besecured thereto in any suitable manner, such as by using one or morethreaded fasteners FST that can extend through the lower structuralcomponent and threadably engage threaded holes 130, which can optionallybe provided in piston 104. Piston 104 is also shown as including asecond or upper end wall 132 that is disposed along upper end 122 andincludes a first wall portion 134 extending generally transverse (e.g.,perpendicular) to side wall 124 and a second wall portion 136 thatextends between and transitions from the first wall portion to side wall124.

While it will be appreciated that any suitable construction and/orarrangement of features can be used in forming piston 104, the exemplaryarrangement shown in FIGS. 3 and 4 illustrate the use of an inner sidewall 134 that extends generally longitudinally between lower and upperends 128 and 132. Additionally, radially-extending support walls 138 canoptionally be included that extend between the inner side wall and theouter side wall.

First open end 110 of flexible sleeve 102 can be secured to the firstend member (e.g., piston 104) in any suitable manner. In the exemplaryarrangement shown, an end closure 140 or other such component can bereceived within the first open end and abuttingly engage first mountingbead 114 such that a substantially fluid-tight seal (e.g., approximatelywatertight or approximately airtight) is formed therebetween. Endclosure 140 can be secured to piston 104 in any suitable manner, such asby using a threaded fastener 142 that threadably engages a correspondingthreaded passage. In the exemplary embodiment shown, a bumper mount 144abuttingly engages end closure 140 and includes a threaded passage 146dimensioned to threadably receive fastener 142. It will be appreciated,however, that any other arrangement and/or configuration couldalternately be used. Optionally, a jounce bumper 148 of any suitabletype, kind, construction and/or configuration can be received on bumpermount 144 and/or otherwise secured within the gas spring assembly.

As discussed above, the second end member of a gas spring assembly canbe secured to the flexible sleeve in any manner suitable for forming asubstantially fluid-tight seal (e.g., approximately watertight orapproximately airtight) therebetween. In the exemplary arrangement shownin FIGS. 1-4, bead plate 106 is secured to second mounting bead 116along second open end 112 of flexible sleeve 102 such that asubstantially fluid-tight seal (e.g., approximately watertight orapproximately airtight) is formed therebetween. As such, a gas or springchamber 150 is at least partially defined by flexible sleeve 102 betweenthe first and second end members.

Bead plate 106 includes an end member wall 152 that can be formed in anysuitable manner and from any suitable material or combination ofmaterials. As one example, end member wall 152 could be formed fromthin-walled metal material, such as steel or aluminum, for example. In apreferred arrangement, the end member wall is formed from a single,unitary section of metal material, such as sheet material or a pre-cutblank, for example, that has a substantially uniform cross-sectionalthickness. The sheet material or blank can then be pressed, stamped orotherwise formed into a desired shape, such as is shown in FIG. 6, forexample, such that the incurrence of additional time and costs may beminimized or at least reduced, such as may be associated with joiningmaterials, machining additional features and/or other manufacturingtechniques and processes, for example. In one preferred arrangement, theend member wall can be formed from a single, unitary section of steelmaterial having a substantially uniform thickness within a range of fromapproximately 1/16 of an inch to approximately ¼ of an inch.Additionally, in a preferred arrangement, the end member wall will havea finished or formed thickness that is approximately uniform and alsowithin a range of approximately 1/16 of an inch to approximately ¼ of aninch.

End member wall 152 is shown in FIGS. 1-6 as including first, second andthird wall portions, which are generally identified by item numbers 154,156 and 158, respectively. First wall portion 154 of end member wall 152includes at least one substantially-flat surface area that at leastpartially defines a first plane PL1 (FIG. 6) of the second end member(e.g., bead plate 106). As one example, the at least onesubstantially-flat surface area of first wall portion 154 can include asurface area 160 that extends at least partially around the outerperipheral extent of the end member wall. In the exemplary embodimentshown, surface area 160 extends circumferentially around the end memberwall in a substantially endless manner. It will be appreciated, however,that any other arrangement and/or configuration could alternately beused.

In the exemplary arrangement shown in FIGS. 1-6, second wall portion 156of end member wall 152 extends from first wall portion 154 out of andaway from first plane PL1 in a first direction, as is generallyrepresented in FIG. 3 by arrow DR1. Prior to assembly, such as isillustrated in FIG. 6, for example, second wall portion 156 can extendin an approximately longitudinal direction and can be approximatelycylindrical in shape. In the alternative, second wall portion 156 can bedisposed at an inwardly or outwardly extending angle with respect tolongitudinal axis AX prior to assembly. Additionally, second wallportion 156 can, prior to assembly, be formed or otherwise disposed inany other suitable shape or arrangement, such as curvilinear and/orfrustoconical shape, for example. Furthermore, second wall portion 156can take any suitable shape, form, arrangement and/or configuration inthe assembled condition, such as is shown in FIGS. 1-4, for example. Inthe exemplary arrangement shown, second wall portion 156 is formed intoa curved shape, such as is represented in dashed lines by item number156′ in FIG. 6, for example, that abuttingly engages and captures secondmounting bead 116 of flexible sleeve 112 such that a substantiallyfluid-tight seal (e.g., approximately watertight or approximatelyairtight) is formed therewith. It will be appreciated, however, thatother arrangements could alternately be used.

Second wall portion 156 is also shown as being disposed radiallyoutwardly of first wall portion 154 such that the second wall portion atleast partially defines an outer peripheral extent of end member wall152. It will be appreciated, however, that other configurations and/orarrangements could alternately be used in which some, if not all, of thesecond wall portion is disposed radially inwardly of the first wallportion such that the first wall portion at least partially defines theouter peripheral extent of the end member wall.

Third wall portion 158 includes at least one substantially-flat surfacearea that at least partially defines a second plane PL2 (FIG. 6) of thesecond end member (e.g., bead plate 106). The at least onesubstantially-flat surface area of the third wall portion is disposed inspaced relation to the at least one substantially-flat surface area offirst wall portion 154 (e.g., surface area 160) in a second directionthat is generally opposite the first direction, as is generallyrepresented in FIG. 3 by arrow DR2. In one exemplary arrangement, firstplane PL1 and second plane PL2 are disposed in approximate alignmentwith one another. An offset is formed between the substantially-flatsurface areas of the first and third wall portions, as is represented bydimension D1 in FIG. 6. The offset, which is represented by dimension D1can be of any suitable value or amount, such as an amount within a rangeof approximately 2 times to approximately 5 times the nominal thicknessof the material from which the end member wall is made. As anotherexample, the offset can be a value or amount within a range ofapproximately 1/32 of an inch to approximately 1¼ inches. In a preferredarrangement, offset D1, in combination with the configuration and/orarrangement of geometric features of the end member wall and inclusiveof any additional geometric features that may be described hereinafter,will be sufficiently large to increase the moment of inertia of the beadplate cross section, after securement to an open end of a flexible wall,by at least a factor of 2 compared with a conventional flat bead plate,after securement to an open end of a flexible wall in substantially thesame manner.

Additionally, third wall portion 158 can optionally include one or morevalleys, which may in the alternative be referred to herein as channelsor grooves, that extend into end member wall 152 in approximately firstdirection DR1. The one or more valleys can separate the at least onesubstantially-flat surface area formed by third wall portion 158 intotwo or more substantially-flat surface area sections that are spacedapart from one another by a valley that is at least partially disposedtherebetween. In the exemplary arrangement shown in FIGS. 1-6, thirdwall portion 158 includes two valleys 162 and 164 that extend lengthwisealong or across the third wall portion of end member wall 152 andseparate the at least one substantially-flat surface area thereof intothree substantially-flat surface area sections, which are identified asfirst, second and third surface area sections 166, 168 and 170. In theexemplary embodiment shown, first and second surface area sections 166and 168 are spaced apart from one another with third surface areasection 170 disposed therebetween.

The one or more valleys formed into the end member wall, such as valleys162 and 164, for example, can take any suitable shape, form,configuration and/or arrangement and can be formed into or otherwiseprovided on the end member wall in any suitable manner. In a preferredarrangement, the material of the end member wall will be stamped,pressed or otherwise deformed into an arrangement or configuration thatincludes the one or more valleys. In the exemplary arrangement shown anddescribed herein, first and second valleys 162 and 164 are formed intothe end member wall such that each valley includes first and second sidewall portions 172 and 174 (FIG. 5) that extend from the at least onesubstantially-flat surface area of the third wall portion inapproximately first direction DR1. Valleys 162 and 164 are also shown asincluding a bottom wall portion 176 that extends between and generallyconnects the first and second side wall portions. In one exemplaryarrangement, bottom wall 176 or a surface thereof can be disposed inapproximate alignment with first wall portion 154 and/or first plane PL1thereof. Alternately, however, the bottom wall could be disposed infirst direction DR1 a distance less than or greater than that offset D1.

Third wall portion 158 also includes an outer periphery 178 thatinterconnects with first wall portion 154. Valleys 162 and 164 canoptionally interface with outer periphery 178 at one or moreintersections. In the exemplary arrangement shown herein, valley 162interfaces with outer periphery 178 at opposing ends of the valley,which are identified by first and second intersections 180 and 182.Similarly, valley 164 is shown as interfacing with outer periphery 178at opposing ends, as are identified by third and fourth intersections184 and 186.

Additionally, the one or more valleys, such as valleys 162 and 164, forexample, can optionally include two or more sections or valley segmentsthat are disposed in approximate alignment and/or otherwise operativelyinterconnected with one another. For example, each of valleys 162 and164 can include first, second and third valley segments, which areidentified by item numbers 188, 190 and 192 in FIG. 2, respectively. Inthe exemplary arrangement shown, first and second valley segments 188and 190 extend in an approximately linear direction and are disposed inapproximate alignment with one another in each of valleys 162 and 164.Additionally, the first and second valley segments of the first andsecond valleys are disposed in approximate alignment such that first andthird intersections 180 and 184 are spaced apart from one anotherapproximately the same distance as second and fourth intersections 182and 186 are from one another. Furthermore, third valley segments 192 ofboth the first and second valleys are non-aligned with the first andsecond valley segments that are interconnected thereby. In thearrangement shown, third valley segments 192 can take a curved or othernon-linear shape.

As discussed above, gas spring assembly 100 can be secured on or alongone or more associated structural components in any suitable manner. Asshown in FIGS. 3 and 4, bead plate 106 is disposed along upperstructural component USC such that the at least one substantially-flatsurface area (e.g., first, second and third surface area sections 166,168 and 170) of third wall portion 158 is in abutting engagement withthe upper structural component. Additionally, as shown in FIG. 3, gasspring assembly 100 is installed in an offset mounting arrangementbetween the upper and lower structural components, which subjects thebead plate and piston to moment or bending loads as the forces acting onthe spring and gas pressure within the spring are transferred throughthe end members. As such, only a portion of the first, second and thirdsurface area sections are abuttingly engaging the upper structuralcomponent.

The second end member can also include one or more securement features,such as may be used to secure the end member on an associate structuralcomponent and/or secure an associated external component (e.g., a gasline fitting) on the second end member. In the arrangement shown, beadplate 106 includes a plurality of securement features, such as, forexample, first and second threaded projections or studs 194 that projectfrom third wall portion 158 in second direction DR2. Optionally, athreaded passage 196 can extend into the end member wall from along thethird wall portion in first direction DR1. A threaded boss 198 can besecured on or along the end member wall, such as by using a welded orbrazed joint JNT, for example, to provide additional strength to theconnection.

In the exemplary arrangement shown in FIGS. 1-6, valleys 162 and 164together with first, second and third surface area sections 166, 168 and170 are arranged or otherwise configured in a manner that establishes aplane of symmetry PSM (FIG. 2) extending longitudinally through endmember wall 152. The valleys and surface area sections are alsoconfigured in a manner that establishes a plane of asymmetry PAS (FIG.2) that also extends longitudinally through the end member wall of thesecond end member. However, plane of asymmetry PAS is disposed ingenerally transverse relation to plane of symmetry PSM. And, both theplane of symmetry and the plane of asymmetry are disposed at leastapproximately along and extend at least approximately throughlongitudinal axis AX (FIGS. 3 and 4) of bead plate 106.

It is to be understood that the planes of symmetry and asymmetrydescribed above are generally established by the one or more valleysextending into and/or otherwise along the end member wall to theexclusion of any securement features that may be disposed on or alongthe end member wall (e.g., first and second threaded studs 194 andthreaded passage 196). That is, the establishment of plane of symmetryPSM and plane of asymmetry PAS is based on the position, orientationand/or configuration of the one or more valleys (e.g., valleys 162 and164) as the same extend into end member wall 152 regardless of theposition, arrangement, orientation and/or alignment of any of the one ormore securement features that may be included on or along end memberwall 152 to form bead plate 106. In the exemplary arrangement shown inFIGS. 1-6, however, first and second threaded projections 194 aredisposed on opposing sides of plane of symmetry PSM and on a common sideof plane of asymmetry PAS. It will be appreciated, however, that otherarrangements could alternately be used.

Another example of an end member in accordance with the subject matterof the present disclosure is illustrated in FIG. 7 as bead plate 106′.It will be appreciated that bead plate 106′ is substantially similar tobead plate 106, such as has been described above in connection withFIGS. 1-6. Thus, certain details that are described above in connectionwith bead plate 106 may not be repeated here but are, nonetheless,intended to apply to or otherwise describe bead plate 106′ unlessspecifically noted otherwise.

Bead plate 106′ includes an end member wall 152′ that includes first,second and third wall portions, which are respectively identified inFIG. 7 using item numbers 154′, 156′ and 158′. Third wall portion 158′includes first and second valleys 162′ and 164′ that can be formed intoor otherwise provided on or along end member wall 152′, such as in amanner similar to that described above in connection with valleys 162and 164, for example. Valleys 162′ and 164′ separate third wall portion158′ into three substantially-flat surface area sections, which areidentified in FIG. 7 using item numbers 166′, 168′ and 170′. Aspreviously described in connection with end member wall 152, first andsecond threaded projections or studs 194′ are disposed along third wallportion 158′ and, as shown, can be positioned on first and secondsurface area sections 166′ and 168′. Optionally, a threaded passage 196′can extend into the end member wall from along third wall portion 158′and, as shown in FIG. 7, can be positioned on third surface area section170′, such as has been described above with regard to threaded passage196 and threaded boss 198, for example.

Third wall portion 158′ also includes an outer periphery 178′ thatinterconnects with first wall portion 154′. First and second valleys162′ and 164′ can optionally intersect with outer periphery 178′, suchas has been discussed above in connection with valleys 162 and 164 andouter periphery 178, for example. Additionally, valleys 162′ and 164′can optionally include two or more sections or valley segments that aredisposed in approximate alignment and/or otherwise operativelyinterconnected with one another. For example, each of valleys 162′ and164′ can include first, second and third valley segments, which arerespectively identified by item numbers 188′, 190′ and 192′ in FIG. 7.

In the exemplary arrangement shown, first and second valley segments188′ and 190′ extend in an approximately linear direction and aredisposed in approximate alignment with one another along each of valleys162′ and 164′. Additionally, the first and second valley segments of thefirst and second valleys are disposed in approximate alignment such thatthe intersections of the valleys with outer periphery 178′ are spacedapart from one another approximately the same distance, such as has beendescribed above. Furthermore, third valley segments 192′ of both thefirst and second valleys are non-aligned with the first and secondvalley segments that are interconnected thereby. In the arrangementshown, third valley segments 192′ can take a curved or other non-linearshape.

Valleys 162′ and 164′, which are shown in FIG. 7, differ from valleys162 and 164 in FIGS. 1-6 in that first and second valley segments 188′and 190′ of valleys 162′ and 164′ are of at least approximately equallength, rather than being of unequal length, as in valley segments 188and 190. As such, third valley segments 192′ are approximately centeredin at least one direction along end member wall 152′. As a result,valleys 162′ and 164′ establish first and second planes of symmetry PSM1and PSM2 through end member wall 152′. The first and second planes ofsymmetry are disposed generally transverse to one another and extend atleast approximately through an axis (e.g., longitudinal axis AX in FIGS.3 and 4) of bead plate 106′.

As described above, however, it is to be understood that the planes ofsymmetry are generally established by the one or more valleys extendinginto and/or otherwise along the end member wall to the exclusion of anysecurement features that may be disposed on or along the end member wall(e.g., first and second threaded studs 194′ and threaded passage 196′).That is, the establishment of the two planes of symmetry PSM1 and PSM2is based on the position, orientation and/or configuration of the one ormore valleys (e.g., valleys 162′ and 164′) as the same extend into endmember wall 152′ regardless of the position, arrangement, orientationand/or alignment of any of the one or more securement features that maybe included on or along end member wall 152′ to form bead plate 106′. Inthe exemplary arrangement shown in FIG. 7, however, first and secondthreaded projections 194′ are disposed on opposing sides of first planeof symmetry PSM1 and in approximate alignment with second plane ofasymmetry PSM2. Additionally, threaded passage 196′ is disposed inapproximate alignment with first plane of symmetry PSM1 and on one sideof second plane of symmetry PSM2. It will be appreciated, however, thatother arrangements could alternately be used.

A further example of an end member in accordance with the subject matterof the present disclosure is illustrated in FIGS. 8-10 as bead plate200. It will be recognized that bead plate 200 is shown prior toassembly on an open end of a flexible sleeve or bellows of a gas spring,such as second open end 112 of flexible sleeve 102, for example, andthat the bead plate can be secured on or along such an open end in anysuitable manner, such as has been described above with regard to beadplate 106 and flexible sleeve 102, for example.

Bead plate 200 is shown in FIGS. 8-10 as including an end member wall202 that can be formed in any suitable manner and from any suitablematerial or combination of materials. As one example, bead plate 200 canbe formed from materials and/or processes similar to those discussedabove in connection with end member wall 152 of bead plate 106. As oneexample, end member wall 202 of bead plate 200 could be formed fromthin-walled metal material, such as steel or aluminum, for example. In apreferred arrangement, the end member wall is formed from a single,unitary section of metal material, such as sheet material or a pre-cutblank, for example, that has a substantially uniform cross-sectionalthickness.

Additionally, such sheet material or pre-cut blank can then be pressed,stamped or otherwise formed into a desired shape, such as is shown inFIGS. 8-10, for example, such that the incurrence of additional time andcosts may be minimized or at least reduced, such as may be associatedwith joining materials, machining additional features and/or othermanufacturing techniques and processes, for example. In one preferredarrangement, the end member wall can be formed from a single, unitarysection of steel material having a substantially uniform thicknesswithin a range of from approximately 1/16 of an inch to approximately ¼of an inch. Additionally, in a preferred arrangement, the end memberwall will have a finished or formed thickness that is approximatelyuniform and also within a range of approximately 1/16 of an inch toapproximately ¼ of an inch.

It will be appreciated that bead plate 200 can be generally similar inoverall construction and configuration to bead plate 106. Certaindetails that are described above in connection with bead plate 106and/or the connection thereof to flexible sleeve 102 and upperstructural component USC may not be repeated here but are, nonetheless,intended to apply to or otherwise describe bead plate 200 as well,unless otherwise specifically described.

End member wall 202 is shown in FIGS. 8-10 as including first, secondand third wall portions, which are generally identified by item numbers204, 206 and 208, respectively. First wall portion 204 includes at leastone substantially-flat surface area that at least partially defines afirst plane PL1 (FIG. 10) of the second end member (e.g., bead plate200). As one example, the at least one substantially-flat surface areaof first wall portion 204 can include a surface area 210 that extends atleast partially around an outer peripheral extent of the end memberwall.

Second wall portion 206 of end member wall 202 extends from first wallportion 204 out of and away from first plane PL1 in a first direction,as is generally represented in FIG. 10 by arrow DR1. Prior to assembly,second wall portion 206 can, as one example, extend in an approximatelylongitudinal direction and can be approximately cylindrical in shape.Second wall portion 206 is also shown in FIGS. 8-10 as being disposedradially outwardly of first wall portion 204 such that the second wallportion at least partially defines an outer peripheral extent of endmember wall 202. It will be appreciated, however, that otherconfigurations and/or arrangements could alternately be used. Forexample, some, if not all, of the second wall portion could be disposedradially inwardly of the first wall portion such that the first wallportion at least partially defines the outer peripheral extent of theend member wall.

Third wall portion 208 includes at least one substantially-flat surfacearea that at least partially defines a second plane PL2 (FIG. 10) of thesecond end member (e.g., bead plate 200). The at least onesubstantially-flat surface area of the third wall portion is disposed inspaced relation to the at least one substantially-flat surface area offirst wall portion 204 (e.g., surface area 210) in a second directionthat is generally opposite the first direction, as is generallyrepresented in FIG. 10 by arrow DR2. In one exemplary arrangement, firstplane PL1 and second plane PL2 are disposed in approximate alignmentwith one another. An offset is formed between the substantially-flatsurface areas of the first and third wall portions, as is represented bydimension D1 in FIG. 10. It will be appreciated that preferred relativedimensions, features and characteristics of offset D1, in combinationwith the configuration and/or arrangement of geometric features of theend member wall and inclusive of any additional geometric features thatmay be described hereinafter, have been described above in detail andare not repeated here.

Additionally, third wall portion 208 can optionally include one or morevalleys, which may in the alternative be referred to herein as channelsor grooves, that extend into end member wall 202 in approximately firstdirection DR1. The one or more valleys can separate the at least onesubstantially-flat surface area formed by third wall portion 208 intotwo or more substantially-flat surface area sections that are spacedapart from one another by a valley that is at least partially disposedtherebetween. In the exemplary arrangement shown in FIGS. 8-10, thirdwall portion 208 includes two valleys 212 and 214 that extend lengthwisealong or across the third wall portion of end member wall 202 andseparate the at least one substantially-flat surface area thereof intothree substantially-flat surface area sections, which are identified asfirst, second and third surface area sections 216, 218 and 220. In theexemplary embodiment shown, first and second surface area sections 216and 218 are spaced apart from one another with third surface areasection 220 disposed therebetween.

Third wall portion 208 also includes an outer periphery 222 thatinterconnects with first wall portion 204. Valleys 212 and 214 canoptionally interface with outer periphery 222 at one or moreintersections. In the exemplary arrangement shown herein, valley 212interfaces with outer periphery 222 at opposing ends of the valley,which are identified by first and second intersections 224 and 226.Similarly, valley 214 is shown as interfacing with outer periphery 222at opposing ends, as are identified by third and fourth intersections228 and 230.

The one or more valleys formed into the end member wall, such as valleys212 and 214, for example, can take any suitable shape, form,configuration and/or arrangement and can be formed into or otherwiseprovided on the end member wall in any suitable manner, such as has beendescribed in detail above in connection with valleys 162 and 164, forexample. Valleys 212 and 214 differ from the valleys that have beenpreviously shown and described herein in that the valleys 212 and 214are disposed in a generally non-aligned arrangement relative to oneanother, whereas at least a portion of valleys 162 and 164 are disposedin approximate alignment with one another. As illustrated in FIGS. 8 and9, valleys 212 and 214 extend along or otherwise across third wallportion 208 in an approximately linear configuration. However, valleys212 and 214 are disposed at an angle relative to one another, as isidentified in FIG. 9 by reference dimension A1. As such, the first andsecond valleys are disposed in an alignment in which the first and thirdintersections 224 and 228 are spaced apart from one another by a firstdistance and the second and fourth intersections 226 and 230 are spacedapart from one another by a second distance that is less than the firstdistance, as is represented in FIG. 9 by reference dimensions D2 and D3,respectively.

As discussed in detail above in connection with other embodiments, beadplate 200 can optionally include one or more securement features, suchas may be used to secure the second end member on an associatestructural component and/or secure an associated external component(e.g., a gas line fitting) on the second end member. In the arrangementshown, bead plate 200 includes a plurality of securement features, suchas, for example, first and second threaded projections or studs 232 thatproject from third wall portion 208 in second direction DR2.Additionally, or in the alternative, one or more passages can extendinto or otherwise be provided on the third wall portion. In theexemplary arrangement shown in FIGS. 8-10, two threaded passages 234extend into the bead plate in approximately first direction DR1. Athreaded boss (not shown) can be secured on or along the end memberwall, such as by using a welded or brazed joint (not shown), forexample, to provide additional strength or support to the threadedconnection along the passages.

In the exemplary arrangement shown in FIGS. 8-10, valleys 212 and 214together with first, second and third surface area sections 216, 218 and220 are arranged or otherwise configured in a manner that establishes aplane of symmetry PSM (FIG. 9) extending longitudinally through endmember wall 202. The valleys and surface area sections are alsoconfigured in a manner that establishes a plane of asymmetry PAS (FIG.9) that also extends longitudinally through the end member wall of thesecond end member. However, plane of asymmetry PAS is disposed ingenerally transverse relation to plane of symmetry PSM. And, both theplane of symmetry and the plane of asymmetry are disposed along andextend at least approximately through an axis of the bead plate, such asis represented by longitudinal axis AX (FIGS. 3 and 4) of bead plate106, for example.

It is to be understood that the planes of symmetry and asymmetrydescribed above are generally established by the one or more valleysextending into and/or otherwise along the end member wall to theexclusion of any securement features that may be disposed on or alongthe end member wall (e.g., threaded studs 232 and threaded passages234). That is, the establishment of plane of symmetry PSM and plane ofasymmetry PAS is based on the position, orientation and/or configurationof the one or more valleys (e.g., valleys 212 and 214) as the sameextend into end member wall 202 regardless of the position, arrangement,orientation and/or alignment of any of the one or more securementfeatures that may be included on or along end member wall 202 to formbead plate 200. In the exemplary arrangement shown in FIGS. 8-10,however, one of threaded projections 232 is disposed in approximatealignment with plane of symmetry PSM and the other of threadedprojections 232 is disposed to one side of plane of symmetry PSM withboth of the threaded projections disposed on a common side of plane ofasymmetry PAS. Additionally, threaded passages 234 are disposed onopposing sides of plane of symmetry PSM and on a common side of plane ofasymmetry PAS. It will be appreciated, however, that other arrangementscould alternately be used.

One advantage of using an end member configured in accordance with thesubject matter of the present disclosure (e.g., bead plates 106, 106′and/or 200) is that additional bending stiffness and strength of the endmember is attained, which is expected to provide improved performance inoffset mounting arrangements. In some cases, it may be possible toeliminate the use of an external reinforcing bracket and/or plate thatmight normally be used to buttress the end member during use in offsetmounting conditions. In other cases, it may be possible to utilize anexternal reinforcing bracket and/or plate of a less robust and, thus,reduced weight construction due to the increased strength andperformance of such an end member. It is anticipated that other benefitsand/or advantages associated with the use of an end member in accordancewith the subject matter of the present disclosure may also be attained.

As used herein with reference to certain elements, components and/orstructures, numerical ordinals (e.g., “first end” and “second end”)merely denote different singles of a plurality and do not imply anyorder or sequence unless specifically defined by the claim language.Additionally, the terms “transverse,” and the like, are to be broadlyinterpreted. As such, the terms “transverse,” and the like, can includea wide range of relative angular orientations that include but are notlimited to an approximately perpendicular angular orientation.Furthermore, the term “gas” is used herein to broadly refer to anygaseous or vaporous fluid. Most commonly, air is used as the workingmedium of gas spring devices, such as those described herein, as well assuspension systems and other components thereof. However, it will beunderstood that any suitable gaseous fluid could alternately be used.

While the subject matter of the present disclosure has been describedwith reference to the foregoing embodiments and considerable emphasishas been placed herein on the structures and structuralinterrelationships between the component parts of the embodimentsdisclosed, it will be appreciated that other embodiments can be made andthat many changes can be made in the embodiments illustrated anddescribed without departing from the principles of the subject matter ofthe present disclosure. Obviously, modifications and alterations willoccur to others upon reading and understanding the preceding detaileddescription. Accordingly, it is to be distinctly understood that theforegoing descriptive matter is to be interpreted merely as illustrativeand not as a limitation. As such, it is intended that the subject matterof the present disclosure be construed as including all suchmodifications and alterations insofar as they come within the scope ofthe appended claims and any equivalents thereof.

1. An end member dimensioned for securement to an open end of anassociated gas spring flexible wall, said end member comprising: an endmember wall having an outer peripheral extent and formed fromthin-walled metal material, said end member wall including: a first wallportion disposed along said outer peripheral extent and including asubstantially-flat surface area at least partially defining a firstplane of said end member; a second wall portion disposed radiallyoutward of said first wall portion and at least partially defining saidouter peripheral extent of said end member wall, said second wallportion extending from said first wall portion out of said first planein a first direction; and, a third wall portion disposed radially inwardof at least part of said first wall portion, said third wall portionincluding a substantially-flat surface area and a plurality of valleysextending depthwise into said end member wall in said first directionand lengthwise across said substantially-flat surface area of said thirdwall portion separating said substantially-flat area of said third wallportion into at least three substantially-flat surface area sections,said substantially-flat surface area at least partially defining asecond plane of said end member that is disposed in approximatealignment with said first plane and in spaced relation to said firstplane in a second direction generally opposite said first direction,said plurality of valleys extending lengthwise across said third wallportion and including: a pair of first valley segments extendinglinearly across said third wall portion in said lengthwise direction andspaced apart from one another in a lateral direction transverse to saidlengthwise direction; at least one second valley segment extendinglinearly across said third wall portion in said lengthwise direction andspaced apart from said pair of first valley segments in at least saidlengthwise direction; and, a pair of third valley segments disposedbetween and interconnecting respective ones of said pair of first valleysegments with said at least one second valley segment; and, a firstsecurement feature disposed along said substantially-flat surface areaof said third wall portion that is adapted to engage an associatedexternal component.
 2. An end member according to claim 1, wherein eachof said plurality of valleys includes opposing side wall portions and abottom wall portion extending between said side wall portions with saidbottom wall portion disposed in approximate alignment with said firstplane.
 3. An end member according to claim 1, wherein said third wallportion includes an outer periphery and at least said pair of firstvalley segments of said plurality of valleys extend lengthwise acrosssaid third wall portion and intersect said outer periphery.
 4. An endmember according to claim 1 further comprising a second securementfeature with said first and second securement features disposed along acommon one of said at least two substantially-flat surface areasections.
 5. An end member according to claim 1, wherein said firstsecurement feature is disposed along one of said at least twosubstantially-flat surface area sections and said end member includes asecond securement feature disposed along a different one of said atleast two substantially-flat surface area sections.
 6. An end memberaccording to claim 5, wherein said first and second securement featuresinclude one of a threaded passage extending into said end member wall inapproximately said first direction and a threaded projection extendingout from said end member wall in approximately said second direction. 7.An end member according to claim 3, wherein said at least one secondvalley segment extends lengthwise across said third wall portion andinterfaces with said outer periphery at at least one intersection.
 8. Anend member according to claim 7, wherein said pair of first valleysegments interface with said outer periphery at first and secondintersections and said at least one second valley segment interfaceswith said outer periphery at at least a third intersection that isdifferent than said first and second intersections.
 9. An end memberaccording to claim 1, wherein at least a portion of said plurality ofvalleys extend in approximate alignment with one another.
 10. A gasspring assembly comprising: a flexible wall extending circumferentiallyaround a longitudinal axis and including a first open end; and a firstend member secured across said first open end such that a substantiallyfluid-tight seal is formed therewith and such that a spring chamber isat least partially defined by said first end member within said flexiblewall, said first end member including an end member wall having an outerperipheral extent and formed from thin-walled metal material, said endmember wall including: a first wall portion disposed along said outerperipheral extent and including a substantially-flat surface area atleast partially defining a first plane of said second end member; asecond wall portion disposed radially outward of said first wall portionand at least partially defining said outer peripheral extent of said endmember wall, said second wall portion extending from said first wallportion out of said first plane in a first longitudinal direction; and,a third wall portion disposed radially inward of at least part of saidfirst wall portion, said third wall portion including asubstantially-flat surface area and a plurality of valleys extendinginto said end member wall, said substantially-flat surface area at leastpartially defining a second plane of said second end member that isdisposed in approximate alignment with said first plane and in spacedrelation to said first plane in a second longitudinal directiongenerally opposite said first direction, said plurality of valleysextending depthwise into said end member wall in said first directionand extending lengthwise along at least a part of said third wallportion, said plurality of valleys including: a pair of first valleysegments extending linearly across said third wall portion in saidlengthwise direction and spaced apart from one another in a lateraldirection transverse to said lengthwise direction; at least one secondvalley segment extending linearly across said third wall portion in saidlengthwise direction and spaced apart from said pair of first valleysegments in at least said lengthwise direction; and, a pair of thirdvalley segments disposed between and interconnecting respective ones ofsaid pair of first valley segments with said at least one second valleysegment.
 11. (canceled)
 12. A gas spring assembly according to claim 10,wherein said substantially-flat surface area of said first wall portionis substantially continuous and extends in a circumferentially endlessmanner about said end member wall of said first end member.
 13. A gasspring assembly according to claim 10, wherein said pair of valleysseparate said substantially-flat surface area of said third wall portioninto at least three substantially-flat surface area sections.
 14. A gasspring assembly according to claim 13, wherein said at least threesubstantially-flat surface area sections includes first, second andthird surface area sections with said first and second surface areasections spaced apart from one another and said third surface areasection disposed therebetween.
 15. A gas spring assembly according toclaim 14, wherein at least one of said first, second and third surfacearea sections includes a securement feature disposed therealong that isdimensioned to engage an associated external component.
 16. (canceled)17. A gas spring assembly according to claim 15, wherein said securementfeature is a first securement feature and said second end memberincludes a second securement feature with said first securement featuredisposed along said first surface area section and said second surfacefeature disposed along said second surface area section.
 18. A gasspring assembly according to claim 15, wherein said securement featureis a first securement feature and said second end member includes asecond securement feature with said first and second securement featuresdisposed a common one of said first, second and third surface areasections. 19-20. (canceled)
 21. A gas spring assembly according to claim10, wherein said pair of third valley segments extend in a non-alignedorientation with respect to said pair of first valley segments and saidat least one second valley segment of respective ones of said pluralityof valleys.
 22. A gas spring assembly according to claim 21, whereinsaid pair of third valley segments include a curvilinear path extendingbetween said pair of first valley segments and said at least one secondvalley segment. 23-24. (canceled)
 25. A gas spring assembly according toclaim 10, wherein said end member wall of said first end member includesat least one longitudinally-extending plane of symmetry.
 26. A gasspring assembly according to claim 25, wherein said end member wallincludes at least first and second longitudinally-extending planes ofsymmetry with said second plane of symmetry disposed transverse to saidfirst plane of symmetry and with one of said first and second valleysdisposed on each side of said first plane of symmetry. 27-34. (canceled)